Method for assembling articles

Abstract

Methods and tools for assembling an article are provided. The method includes providing a mold having a cavity configured as a desired shape, positioning a base within the mold so that a surface of the base material is exposed, applying a coating material, e.g., urethane or polyurethane, to substantially cover both the exposed surface of the base and an inner surface of the cavity, depositing a cushion material into the cavity and sealing the cavity with the exposed surface of the base so that the coating material forms a skin around the cushion material and adheres the cushion material to the base.

1 . A method of assembling an article, the method comprising the steps of: 
 providing a mold having a cavity configured as a desired shape;    positioning a base within the mold so that a surface of the base material is exposed;    applying coating material to substantially cover both the exposed surface of the base and an inner surface of the cavity; and    depositing a cushion material into the cavity and sealing the cavity so that the coating material forms a skin around the cushion material and adheres the cushion material to the base.    
     
     
         2 . The method of  claim 1  wherein the coating material is comprised of urethane.  
     
     
         3 . The method of  claim 1  wherein the coating material is comprised of polyurethane.  
     
     
         4 . The method of  claim 1  wherein the applying the coating material includes spraying the coating material.  
     
     
         5 . The method of  claim 1  wherein the cushion material comprises an expandable foam.  
     
     
         6 . The method of  claim 5  wherein the expandable foam comprises an expandable isocyanate foam.  
     
     
         7 . The method of  claim 1  wherein the cushion material comprises one or more different materials.  
     
     
         8 . The method of  claim 1  wherein the base is a flame treated base.  
     
     
         9 . The method of  claim 1  wherein the cavity of the mold has a surface including one or more features so that the coating material retains such features when it forms a skin.  
     
     
         10 . The method of  claim 9  wherein the one or more features is selected from the group consisting of decals, fabrics, vinyls, leathers, rubbers and paints.  
     
     
         11 . The method of  claim 9  wherein the one or more features includes textures.  
     
     
         12 . The method of  claim 1  wherein the mold includes a lid and the positioning a base within the mold so that a surface of the base is exposed comprises removably attaching the base to the lid.  
     
     
         13 . The method of  claim 12  wherein the sealing the cavity with comprises closing the lid.  
     
     
         14 . The method of  claim 1  wherein the mold comprises a first portion and a second portion, the first portion adapted to receive the base and the second portion configured as a cavity, wherein sealing the cavity comprises sealing the first and second portions together.  
     
     
         15 . The method of  claim 14  wherein the positioning a base within the mold so that a surface of the base material is exposed comprises loading the base into the first portion so that a surface of the base is exposed.  
     
     
         16 . A method of assembling an article, comprising the steps of: 
 applying coating material into a cavity of a mold that defines a desired profile;    depositing expandable cushion material into the cavity of the mold;    closing a lid of the mold and allowing the expandable cushion material to expand to a volume defined by the mold and the lid;    opening the lid; and    adhering a base to the expandable cushion material by applying a coating material between the base and the expandable cushion material.    
     
     
         17 . The method of  claim 16  wherein the coating material is comprised of urethane.  
     
     
         18 . The method of  claim 16  wherein the coating material is comprised of polyurethane.  
     
     
         19 . The method of  claim 16  wherein the applying the coating material includes spraying the coating material.  
     
     
         20 . The method of  claim 16  wherein the expandable cushion material comprises one or more expandable foams.  
     
     
         21 . The method of  claim 20  wherein at least one expandable foam comprises an expandable isocyanate foam.  
     
     
         22 . The method of  claim 16  wherein the base is a flame treated base.  
     
     
         23 . The method of  claim 16  wherein the cavity of the mold has a surface including one or more features so that the coating material retains such features when it forms a skin.  
     
     
         24 . The method of  claim 23  wherein the one or more features is selected from the group consisting of decals, fabrics, vinyls, leathers, rubbers and paints.  
     
     
         25 . The method of  claim 23  wherein the one or more features includes textures.  
     
     
         26 . The method of  claim 16  wherein the lid contains an underside which projects into the cavity to impart a shape in the expandable cushion material once expanded.  
     
     
         27 . The method of  claim 26  wherein the base is configured to mate with the shape in the expandable cushion material created by the underside.  
     
     
         28 . The method of  claim 26  wherein the underside of the lid further includes a protrusion which projects deeper into the cavity than the underside to impart a shape in the expandable cushion material once expanded to form a breathable cavity.  
     
     
         29 . The method of  claim 28  wherein the base is configured to mate with the shape in the expandable cushion material created by the underside so that the breathable cavity is formed between the base and the expandable cushion material.  
     
     
         30 . The method of  claim 16  further comprising removing the expandable cushion material from the cavity and placing the expandable cushion material into a cavity of a secondary mold before adhering the base to the expandable cushion material.  
     
     
         31 . The method of  claim 30  wherein the opening of the cavity of the secondary mold is larger than the opening of the cavity from which the expandable cushion material is removed.  
     
     
         32 . The method of  claim 16  further comprising removing the expandable cushion material from the cavity and placing the expandable cushion material into a fixture prior to adhering the base to the expandable cushion material.  
     
     
         33 . The method of  claim 32  wherein applying a coating material between the base and the expandable cushion material comprises placing a bead of coating material between the base and the expandable cushion material.  
     
     
         34 . The method of  claim 16  wherein applying a coating material between the base and the expandable cushion material seals the expandable cushion material with the coating material.  
     
     
         35 . The method of  claim 16  wherein applying a coating material between the base and the expandable cushion material does not seal the expandable cushion material with the coating material.  
     
     
         36 . The method of  claim 35  wherein a vapor permeable, liquid impermeable membrane is applied to the article to seal the expandable cushion material from liquid.  
     
     
         37 . An article comprising a base and a cushion material having a skin comprised of a coating material, wherein the base and the cushion material are bonded together by the coating material.  
     
     
         38 . The article of  claim 37  wherein the coating material is comprised of urethane.  
     
     
         39 . The article of  claim 37  wherein the coating material is comprised of polyurethane.  
     
     
         40 . The article of  claim 37  wherein the cushion material further includes an outer protective covering.  
     
     
         41 . The article of  claim 40  wherein the outer protective covering is comprised of urethane.  
     
     
         42 . The article of  claim 40  wherein the outer protective covering is comprised of polyurethane.  
     
     
         43 . The article of  claim 40  wherein the outer protective covering further includes one or more features.  
     
     
         44 . The article of  claim 43  wherein the one or more features is selected from the group consisting of decals, fabrics, vinyls, leathers, rubbers and paints.  
     
     
         45 . The article of  claim 43  wherein the one or more features includes textures.  
     
     
         46 . The article of  claim 37  wherein the article is a seat for a vehicle.  
     
     
         47 . An article comprising a base and a cushion material having a skin comprised of a coating material, the article being made according to the method of  claim 1 .  
     
     
         48 . A vehicle having a seat made according to the method of  claim 1 .  
     
     
         49 . The vehicle of  claim 48  wherein the vehicle is selected from a group consisting of a motorcycle, moped, scooter, all terrain vehicle, utility vehicle, and personal watercraft.